Modelling of metal–mold interface resistance in the A356 Aluminium alloy casting process

In this study, a computational model has been developed for determination of metallostatic pressure on the heat transfer coefficient, resistance of metal–mold interface and solidification time for solving of heat transfer equations. The simulation of interface resistance is based on the zero thickness element (ZTE), using the finite element method (FEM). The solid boundary conditions, including contact resistance have been modified by pressure gradient in each ZTE. The pressure gradient has been imposed by an experimental function, which obtained based on experimental data. In order to verify the computational results, an A356 Aluminium alloy has been poured into a permanent mold and temperature of interface was measured by data acquisition system. The comparison between the experimental and the simulation results during solidification process shows a good agreement that confirms the accuracy of the model in order to simulate the effect of interface resistance on the solidification time. Copyright © 2006 John Wiley & Sons, Ltd.